I just had to replace my Rugged Ridge exhaust header as it cracked (returned under warranty). Nick (kolak) suggested instead of staying with Rugged Ridge I go with Doug Thorley header as they had some in stock this time.

I received it and installed it no problem except it has a 3 bolt flange for the down pipe and seems to be in a different position then stock slightly. Now I dont have a welder so I have been trying to figure out some way to make it fit with no luck .

Can I drive it with no down pipe (muffler Cat and O2 sensors) just long enough to get to a shop to have it all welded up?

Also I need to do the rear Main seal soon is it work having them cut and put a joint in just before the cat so I can remove the section of pipe from the header to the Cat as I hear its in the way for doing the rear main seal?

Do you have AAA or towing on your insurance? If so just tell them it's broke and needs towed to a shop. If not make a slow run for it, don't back your engine down a bunch letting cool air go up the header, and it should be fine.

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I will give it one more go at tying them together somehow then I will drive it to the shop!

UniBlurb, what do you mean not backing down my engine? Should I try keeping it at a constant RPM as much as possible?

What I mean is don't have the engine revved high then let off of the accelerator real quick where it may backfire and the back pressure could suck cool air into the hot engine. Try coming to a stop slowly, less noise, and constant rpms would be the best. Good luck.

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It's too bad you won't be able to see it....if you run it to high RPM's and then chop the throttle you can get some nice flames out the exhaust! How do I know this...lol...I do this with my bike....and get some AWESOME flamage!! Can scare the crap out of riders beside you though! But that's what running an 18" open pipe can do! Hellz ya! It won't hurt the engine.